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XJ550 Clutch Installation

Discussion in 'XJ Technical Chat' started by laxjosh1223, Sep 25, 2009.

  1. laxjosh1223

    laxjosh1223 New Member

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    I was having some trouble shifting on my XJ550 SECA. When downshifting coming to a stop, I couldn't shift from 3 to 2. I had to jimmy the bike around when I got stopped to get it down into 1. After looking around on the site, I gathered that it might be the shifter springs, so I installed new springs on the shift assembly. I reinstalled the clutch and now I can't seem to get the clutch to fully disengage. I did some investigative fiddling and found that when I torque the compression spring bolts down to a lower torque than the required 5.8 ft-lb that the clutch will disengage more easily. I have since ordered new compression springs and I am planning on replacing the cable as well. Hopefully that will should be the fix. The reason I posted is that I have read through some other posts on clutches and have seen a few people say that the 550's clutches have some intricacies that other bikes don't have. I have the service manual, but it seems like it is less than thorough. Are there any step by step write ups on the 550 clutches?

    Thanks in advance!
     
    laxjosh1223, Sep 25, 2009
    #1
  2. JFStewart

    JFStewart Member

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    I PM'd a message to you. I have a good procedure available.
     
    JFStewart, Sep 25, 2009
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  3. Bushy

    Bushy Active Member

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    Try Rickomatic's clutch adjustment guide, the link is in his signature, it worked for me. How many miles, maybe you need new plates as well. Oil type and weight need to be right, something not synthetic, no friction modifiers, ' bout 10-40w.
     
    Bushy, Sep 25, 2009
    #3
  4. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    I'm working on the photo how-to. The 550's plain plates have a tab on one side, to intentionally create an "out of balance" condition, supposedly to minimize rattle.

    These plates go in with the tabs spaced at 72* intervals (1/5 of a revolution) which roughly corresponds to the bolt bosses. First plain plate, tab straight up; friction plate; next plain plate, tab at 72* rotated, friction plate, next plain plate another 72* further rotated, etc.

    There is one friction plate with a larger ID than the others, it has a "clutch boss spring" (a giant "wave washer") that fits into the larger ID. This plate/spring combo goes in the 3rd position in from the outside.
     
    bigfitz52, Sep 25, 2009
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